Kawasaki EL250 Eliminator & 250HS Service Manual Set, 1988–1995 (P/N 99924-1066-01)

Use the supplement for EL250-specific specifications and procedures and the base manual for shared service work. Together they let mechanics check component wear and plan rebuilds against the correct factory data.

The base PDF skips printed Final Drive pages 10-4 and 10-5, which cover chain slack, rear-wheel alignment, and the start of the chain-wear inspection. The supplement provides the EL250-specific changes for chain slack and alignment, along with its own chain removal and installation procedures.

PDF Files and Wiring Diagram Detail

Search and diagram readability: Neither PDF has text search or embedded bookmarks. Both have a quick-reference guide and chapter contents. Zoom in to read small wire-color codes and connector labels on the full-bike diagrams.

The ZIP contains two printable PDFs totaling 368 pages, including seven preliminary pages in each PDF and the 14-page EL250E section within the supplement. The 54 parts illustrations and one EL250-E wiring image are separate files outside the PDF page count.

Carburetor, Engine, Chassis, and Electrical Service

The list below gives selected workshop topics. The manuals also cover jobs such as speedometer gear housing service and throttle cable routing.

• Carburetor repair: Step-by-step instructions cover removal, disassembly, and cleaning of the Keihin CVK units, along with inspection, synchronization, and fuel-level adjustment.

• Cooling system: Pressure testing, radiator-cap and thermostat inspection, water-pump removal and installation, and coolant bleeding.

• Engine top end: Compression testing, cylinder-head repair, valve-clearance adjustment, valve-seat refinishing, camshaft-chain timing, and piston-ring inspection.

• Engine and transmission: Engine removal, crankcase splitting, crankshaft and balancer inspection, wet multi-plate clutch service, and internal transmission repair.

• Brakes: Front caliper and master-cylinder repair with hydraulic bleeding, plus EL250 rear-drum shoe and brake-cam inspection.

• Suspension and steering: Fork disassembly and seal replacement, twin-shock adjustment, swingarm-bearing inspection, and steering-stem service.

• Electrical diagrams: Full-bike wiring layouts for EL250-B2 and early B3, late B3, and EL250-E1, plus charging and ignition circuit diagrams.

Kawasaki wrote these manuals primarily for mechanics in equipped shops. The basic maintenance and repair sections also suit owners who have mechanical knowledge and are familiar with the proper tools and workshop procedures.

EL250 Fuel, Cooling, and Chassis Differences

The EL250 supplement gives the specifications and procedures for its CVK30 carburetors, rear drum brake, and twin rear shocks. The base manual describes the EX250’s CVK32 carburetors, rear disc brake, and Uni-Trak suspension.

The Cooling System exploded view identifies the revised water-pump assembly by engine serial number. For California models, the evaporative-emissions coverage shows hose routing for the canister and liquid/vapor separator and includes inspection and a separator operation test.

Crankshaft, Gearbox, and Lubrication

Color-coded bearing-insert tables match crankpin and main-journal measurements with component marks to identify replacement inserts. The gearbox section covers shift-fork, drum-groove, and gear-dog wear, along with service of the positive neutral finder. The Engine Oil Flow Chart shows how oil reaches the crankshaft and camshafts and accompanies the oil-pressure measurement and relief-valve checks.

The top-end notes explain how misplaced camshaft caps can alter bearing clearance and cause seizure. The carburetor section warns that compressed air can damage floats and vacuum-piston diaphragms in an assembled carburetor.

Electrical Tests and Fault Tracing

Component checks cover the alternator, regulator/rectifier, ignition coils, and IC igniter. Starter-motor inspection covers the brushes, commutator, and armature. The Junction Box Internal Circuit shows connector pin positions for relay, diode, and continuity checks.

Separate B3 cooling-fan layouts help identify the applicable circuit before testing. The 250HS chapter adds a Tachometer Circuit diagram and coolant-temperature warning-system tests. The symptom-based troubleshooting guide covers hard starting, poor running, overheating, clutch problems, and shifting faults.

Follow the manual’s precautions for fuel handling, brake service, and unexpected cooling-fan operation.

Workshop Tools and Sample Cooling and Brake Specs

Component torque tables, fluid capacities, wear limits, and electrical test values accompany the repair procedures. Cylinder-head bolt and axle nut torque figures are given in newton-meters and foot-pounds. Tool references include the Fuel Level Gauge 57001-1017, Clutch Holder 57001-1243, and Coil Tester 57001-1242.

For EL250-B2/B3 thermostat testing, the supplement specifies an opening range of 80.5–83.5°C (177–182°F) and a minimum full-open lift of 6 mm at 95°C (203°F).

For the EL250-B2/B3 rear drum brake, the supplement gives a standard pedal free play of 20–30 mm and illustrates where it’s measured.